Heat exchanger tube plug installation

ABSTRACT

A method of tube plug installation in a heat exchanger or pressure vessel is provided. The method includes verifying the suitability of a selected tube plug with a specifically identified type of heat exchanger or pressure vessel before installation of the selected tube plug. The step of verifying being performed with a device having an app, software, or user interface and after having entered or accessed data concerning the selected tube plug and entering or accessing data concerning the specifically identified type of heat exchanger or pressure vessel and operating parameters of the specifically identified type of heat exchanger or pressure vessel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of co-pending U.S. application Ser. No.17/395,568 filed Aug. 6, 2021.

BACKGROUND

The present invention relates to the installation of heat exchanger tubeplugs, and more particularly, the present invention relates to a methodof confirming and reporting successful tube plug installation andequipment or devices capable of recording or transmitting tube pluginstallation data.

Mechanically expanded heat exchanger tube plugs are used to block offtubes in heat exchangers and pressure vessels, usually due to damage orwear.

By way of example, shell and tube-type heat exchangers customarilycomprise a bundle of tubes mounted in spaced parallel relation atopposite ends in tube sheets. The tube bundle is surrounded by a shellthrough which a medium is flowed between an inlet and an outlet of theshell. Heads are provided on opposite ends of the shell to afford theflow of another medium through the interior of the tube bundles. Inmultiple pass heat exchangers, one head end of the heat exchanger may beprovided with flow reversing means to cause the fluid to flow withinselected tubes and make several passes before exiting the heatexchanger.

Heat exchangers of the above type have been known to fail in use and torequire repair. Generally, this is accomplished by removing the head atopposite ends of the tube, and either removing, or replacing, thedefective tube, or plugging the defective tube. Since such heatexchangers are often integral components of continuous plant processes,it is important that they be repaired quickly within a minimum ofdowntime.

Various types of plugs are known for sealing off defective tubes. Atypical plug assembly comprises a radially deformable ring adapted to beplaced in a tube of a heat exchanger in alignment with its tube sheetand an elongated pin having a conical shape with a constant taper alongits length which is slidably received within the ring for expanding thering outwardly when the pin is pulled axially relative to the ring. U.S.Pat. No. 5,437,310 issued to Cunningham and U.S. Pat. No. 4,425,943issued to Martin provide examples.

As the pin is advanced through the ring, the ring expands and compressesagainst an inner diameter wall of a tube thereby forming ametal-to-metal seal. A breakaway member is mounted at the narrow end ofthe pin and is connected to a pull rod which cooperates with acompression tube engaging the sleeve to pull the pin into the ring andexpand the ring outwardly to provide a fluid type of joint. After apredetermined amount of outward pressure has been applied, the breakawayruptures to permit removal of the pull rod and compression tube fromwithin the plugged tube.

Many different permutations of sizes, materials, and plug specificationsexist. This is due to the fact that many heat exchangers are customdesigned for specific applications. As a result, many varieties of tubesizes, materials, and operating parameters exist.

It is common to find hundreds of different heat exchangers at one siteor plant. This is especially true for plants that sustain criticalinfrastructure, such as refineries, chemical processing plants,conventional power generating stations, and nuclear generating stations.In the case of nuclear generating stations, correct product selectionand installation is a matter of public safety. The incorrect use orinstallation of a tube plug could allow radiation to escape and causeexposure to the public.

These industries desire increased safety, traceability, and reliability,and in the case of heat exchanger tube plugs, providing maximum safetyrequires the correct product choice, the ability to review what type ofplug was installed and where, and confirmation that every tube plug wascorrectly installed.

SUMMARY

According to an aspect of the present invention, a method of tube pluginstallation in a heat exchanger or pressure vessel is provided. Themethod includes verifying the suitability of a selected tube plug with aspecifically identified type of heat exchanger or pressure vessel beforeinstallation of the selected tube plug. The step of verifying isperformed with a device having an app, software, or user interface andafter having entered or accessed data concerning the selected tube plugand entering or accessing data concerning the specifically identifiedtype of heat exchanger or pressure vessel and operating parameters ofthe specifically identified type of heat exchanger or pressure vessel.

The method may include a step of confirming tube plug installationsuccess or failure based on at least one real-time measurement takenduring installation and an analysis thereof In addition, the method mayinclude a step of retaining plug installation data and an associationwith a specific tube location of the heat exchanger or pressure vessel.

According to another aspect of the present invention, a devicecomprising at least one processor configured to verify suitability of aselected tube plug with a specifically identified type of heat exchangeror pressure vessel before installation of the selected tube plug isprovided. The device has at least one of an app, software, or userinterface and is configured to receive or access data concerning theselected tube plug and to receive or access data concerning thespecifically identified type of heat exchanger or pressure vessel andoperating parameters of the specifically identified type of heatexchanger or pressure vessel.

The device may be an electronic device, smartphone, computer, tablet, orlaptop or an installation tool configured to obtain real-timemeasurements of installation parameters. The at least one processor mayalso be configured to confirm tube plug installation success or failurebased on at least one real-time measurement taken during installationand an analysis thereof. The at least one processor may be configured toretain plug installation data and an association with a specific tubelocation of the heat exchanger or pressure vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention should becomeapparent from the following description when taken in conjunction withthe accompanying drawings, in which:

FIG. 1 is a flowchart of a method of verification of correct plug choiceand installation according to an embodiment.

FIG. 2 is an image of an installation tool for capturing data, measuringinstallation parameters, and/or for reporting installation parametersaccording to an embodiment.

FIG. 3 is an image of the user interface on the tool of FIG. 2 accordingto an embodiment.

FIG. 4 is an image of the user interface of FIG. 3 providing feedbackafter plug installation according to an embodiment.

FIG. 5 is an image of a user interface of an App for use in searching,selecting, or adding a job number according to an embodiment.

FIG. 6 is an image of a user interface of the App for use in displayinginformation concerning installation setup and details of a job number inaccordance with an embodiment.

FIG. 7 is an image of a user interface of the App for use creating a newjob number in accordance with an embodiment.

FIG. 8 is an image of a user interface of the App for use in enteringdata concerning a new plug to be installed in accordance with anembodiment.

FIG. 9 is an image of a barcode including a list of informationcontained by the barcode in accordance with an embodiment.

FIG. 10 is a listing of information provided by a lot number tableobtainable from a cloud server or the like in accordance with anembodiment.

FIG. 11 is an image of a user interface of the App for displaying areport in accordance with an embodiment.

FIG. 12 is an image of a user interface of the App for sending orprinting a report in accordance with an embodiment.

FIG. 13 is an image of a user interface of the App for setting up andentering new equipment or users in accordance with an embodiment.

FIG. 14 is an image of a user interface of the App for viewing,searching, modifying, or entering equipment in accordance with anembodiment.

FIG. 15 is an image of a user interface of the App for viewing,searching, modifying, or entering users/technicians in accordance withan embodiment.

FIG. 16 is an image of a user interface of the App providing additionaloptions in accordance with an embodiment.

FIG. 17 is a graph showing force versus ring travel on the pin of a plugobtained by a production test stand in accordance with an embodiment.

FIG. 18 is a graph showing cylinder pressure of an installation toolversus time obtained by use of an installation tool in accordance withan embodiment.

DETAILED DESCRIPTION

While best practices may be available to help installers of tube plugsto prevent incorrect tube plug product selection and installation, thereare still opportunities for mistakes to occur when installing a tubeplug. In most industries, mistakes are not acceptable, as they causeunplanned outages, damage to equipment, and compromised safety.

Conventional technical guides and resources may assist in correct tubeplug product selection. In addition, many mistake proof installationfeatures are designed into the tube plugs themselves. Still, given theconventional state of the art and practices, improvements with respectto installing tube plugs is desired.

Embodiments disclosed herein provide a method enabling installers toreadily analyze tube plug installations in heat exchangers and pressurevessels and to determine whether or not the correct repair method isbeing selected and whether or not an installation was successful. Themethod may be carried out with software on an electronic device, such asan app on a smartphone or like handheld electronic device, software on acomputer, tablet, laptop, or like electronic device, or with the use ofa user interface provided on a specialized installation tool, device, orequipment. These devices may provide indications of plug installationstatus.

Accordingly, embodiments disclosed herein provide a method, software,and devices or tools for informing a plug installer at the time ofinstallation that the plug they have chosen to install is correct, toconfirm after installation that all key installation characteristicswere acceptable and within a specified range, and/or to document theinstallation of a plug in a tube as proof that a tube is plugged with acorrectly specified and installed plug.

Thus, according to at least some contemplated embodiments, a pluginstaller may first be provided with the opportunity and ability toverify that the correct and proper tube plug for any given heatexchanger is being installed at the time of installation. Key operatingparameters for the heat exchanger may be entered into a database. Thismay occur at the time of installation or well before installation andsuch data will be accessible by the software, app, device, or tool.Thus, before installation, the user will use the software, app, tool, ordevice to make a selection of which specific type of heat exchanger isbeing plugged and will then enter information about the plugs that havebeen preliminarily chosen for installation (i.e., by entering a lotnumber, scanning a bar/QR code, etc.). The working limits of theselected tube plug is automatically compared to the operating limits ofthe particular heat exchanger by the software or app to confirm that thecorrect and proper tube plug has been chosen. The software, app, tool,or device may provide visual or audible information to the installer asto whether or not the tube plug selected is acceptable for installation.

The method performed by the software or app may also include thecollection of data concerning specific heat exchanger operatingparameters, such as design temperature and pressure, and an evaluationof the data relative to tube plug design limits to ensure compatibility.The method performed by the software or app may also include a step ofcomparing metallurgical properties of the host tubes of the heatexchanger or pressure vessel and selected tube plugs to ensurecompatibility. Further, information on tube sizing and tube installationparameters, or actual tube inner diameter (ID) measurements, may becompared to the plug size operating range. After the heat exchangerrequirements and information are collected, entered, and evaluatedagainst the tube plug specifications and characteristics, approval toinstall a plug may be given by the app, software, or user interface ofthe installation tool.

After the plug choice has been verified as discussed above, theinstaller designates the tube location relative to the specific heatexchanger or pressure vessel into which the plug is being installed.This allows the app or software to automatically evaluate whether or nota complete heat exchanger repair job was properly accomplished—forinstance, it may detect that only one end of a tube was plugged insteadof both ends. Additionally, the method using the software or app ensurestraceability for which lot of tube plugs was installed in whichparticular tube. For instance, in the event of a recall of a particularlot of plugs, removing the recalled product would limit the removal ofplugs solely to the affected lot as stored by the software or app, andnot to all of the plugs in a heat exchanger.

The method carried out by use of the app, software, or the like mayinclude collecting data from the plug installation and evaluating thedata to determine if the plug was installed correctly. Tube plugs areessentially “destroyed” when installed. There is no actual way toreadily determine whether or not a tube plug has been correctlyinstalled after the installation takes place. The only way to determinethis is to collect and evaluate data obtained during the installationprocess.

For this purpose, the method may use measurable characteristics thatwill aid in determining whether or not a tube plug has been successfullyinstalled. Lot testing of tube plugs in a laboratory setting isaccomplished to ensure performance. The method evaluates this storeddata and automatically determines with the software or app whether ornot the plug was successfully installed, which allows the end user to“test” every tube plug that is installed in the field.

Further, the method automatically creates and retains records of pluginstallation data with the software or app for each plugged tube in theheat exchanger. Having the ability to analyze installation data providesadvanced troubleshooting capabilities in the event of a plug failure.This enables various types of advanced reporting. Plugs installed perday, per week, per year, per outage, per job, per user, etc. can bereported. The method provides the ability to see how many tubes wereplugged at any given time per heat exchanger, so metrics such as processefficiency and plugged tubes can be evaluated. Thus, unprecedentedaccess to plug installation and heat exchanger plugging data is providedvia use of the software, app, or specialized installation tool.

According to some embodiments, a specialized device, equipment, orinstallation tool may be provided for use in collecting data during tubeplug installation in a heat exchanger or pressure vessel. The device orinstallation tool may be able to collect and transmit or communicatethis data to another device, such as a smartphone, tablet, computer,server or the like where the data can be analyzed and evaluated againstcertain criteria. Alternatively, the device, equipment, or installationtool may be a standalone device and may have the capability of analyzingcollected data and providing feedback on plug installation. Additionalfunctionality and capabilities may be added to the installationequipment and/or software.

By way of example, FIG. 1 provides logic 10 that may be implemented insoftware, an app, or the like for use in determining if a pluginstallation was completely successful. In this example, the installerwould first select and enter a selected type of plug and would alsoidentify the particular type of heat exchanger in which the plug is tobe installed. Then, the software or app would perform numerous pass/failverifications. For instance, in step 12, plug rated pressure versusoperating pressure that will be experienced by the plug afterinstallation is verified (i.e., pass/fail). In step 14, plug ratedpressure versus hydrotest pressure is verified (i.e., pass/fail). Instep 16, plug rated temperature versus operating temperature that willbe experienced by the plug after installation is verified (i.e.,pass/fail). In step 18, compatibility of plug material versus tubematerial is verified (i.e., pass/fail). In step 20, compatibility ofplug size versus expended tube inner diameter (ID) is verified (i.e.,pass/fail).

If any of these verifications fail (see steps 22), then the analysis isconcluded, and the issue is reported to the installer via a visual oraudible indication. If this occurs, the installer must select adifferent tube plug. The software or app may provide suggestions.

Alternatively, if the selected tube plug passes all the verifications,then installation of the selected tube plug is approved (see step 24)and the approval may be reported to the installer via visual or audibleindication. Thereafter, the installation may be completed (see step 26)and then verified. For instance, in step 28, measured installation forceused to install the tube plug versus stored guidelines is verified(pass/fail). In step 30, an installation pressure graph for chatters(galling) is analyzed (pass/fail). In step 32, the installation pressuregraph for expected travel is analyzed (pass/fail).

If any of these verifications fail (see steps 34), then the analysis isconcluded, and the installer is alerted via visual or audible indicationto remove the installed plug. If this occurs, the installer must removethe plug, install a new tube plug, and repeat these verifications.

Alternatively, if all of the verifications pass, then a confirmation ofthe installation is provided in step 36. If any red flags are detectedduring these verifications, one or more messages are automaticallygenerated in step 38 and provided to the user on a display of the deviceor the like. The messages may describe the area of concern detected.Whether or not any red flags are generated, the process proceeds to step40 which provides an indication that installation verification has beensuccessfully completed.

As stated above, all or some of the above steps may be performed on anapp of smartphone or the like, software of a computer or the like, orvia a user interface provided on specialized equipment, devices, ortools.

FIG. 2 provides an example of an installation tool 42 for use by theinstaller for accomplishing all or some of the steps of the abovereferenced process. The tool 42 may automatically capture data during aninstallation process and may have wireless communication abilities orthe like. For instance, the data may include actual measuredinstallation force, travel, or the like. The tool 42 may transmit thesemeasurements to a device provided with the app or software or may be astandalone tool and contain processors or the like used to analyze thedata.

FIG. 3 shows a part of the tool 42 having a user interface displayscreen 44 that shows measured data (i.e., installation force). FIG. 4shows the user interface display screen 44 after installation of a tubeplug displaying feedback concerning the installation (i.e., “OK” or notOK).

In view of the foregoing, it should be apparent that embodimentsdisclosed herein provide a Tube Plug Installation app, software, ordevice which can be used to confirm and report successful tube pluginstallation.

A device or system for carrying out any of the above disclosedembodiments, methods, or arrangements may include software or the likeprovided on a circuit board or within another electronic device and caninclude various processors, microprocessors, modules, units, components,controllers, chips, disk drives, communication circuits, and the like.It will be apparent to one of ordinary skill in the art that systems,modules, components, units, processors, servers, and the like may beimplemented as electronic components, software, hardware or acombination of hardware and software for purposes of providing a system.

Embodiments may also include at least one non-transitory computerreadable storage medium having computer program instructions storedthereon that, when executed by at least one processor, can cause the atleast one processor to perform any of the steps described above.

Example—User Interface

By way of example and not by way of limitation, FIGS. 5-16 show a device50, such as a smartphone, on which an App is installed and show variousgraphical user interfaces and screen views that may be presented to auser of the App. The App enables data to be captured during installationof plugs or like products that are actually being installed and used ina heat exchanger or pressure vessel. The App permits reports to begenerated and printed or electronically forwarded, setup procedures tobe accomplished, details concerning new or existing installation jobs tobe entered, as well as additional options. Accordingly, as discussedabove, the App can be used to provide confirmation of proper oracceptable installation, generate reports, ensure process traceabilityand conformance, and simply installation process.

As best shown on FIG. 5 , the App or software may be downloaded onto thedevice 50, such as a smartphone. The user interface of the App mayinclude an App control menu 52 including multiple icons, such as oneeach for “Jobs” 54, “Reports” 56, “Setup” 58, and “More” 60. If the“Jobs” icon 54 is selected, an interface such as shown in FIG. 5 may bepresented. This interface may include a search line 62 permitting asearch for a particular job number. If the job number is located,information concerning job status (completed or in process), equipmentjob ID, equipment description, date the job was last modified, and thelike may be displayed. See FIG. 5 . The interface may also include a“New Job” icon 64 which enables a new job number to be created, and theinterface may include a filter icon 66 enabling a search of stored jobentries by date period or the like and sorted by status, equipment tagID, job number or the like.

If a particular job number is selected, for instance as shown in FIG. 6, information concerning “installation setup” 68 may be displayed. Thismay include, for instance, job number, equipment tag ID, plant name,unit number, technician name, rated pressure, hydrotest pressure, ratedtemperature, and the like. In addition, information concerning“installation details” 70 may be displayed. This may include the numberof plugs installed in the selected job, a link to a list of installedplugs, installation status (pass or fail), plug location, plugorientation, plug part number, plug lot number, and the like. Aninstallation report icon 72 may be provided for obtaining and/orgenerating an installation report. In addition, a complete or lock jobicon 74 or install next plug icon 76 may also be provided to complete orlock a current job or to enter data concerning a next plug to beinstalled.

If the “New Job” icon 64 is selected, such as shown in FIG. 7 ,information concerning the job is entered by the user. For instance, anew job number is entered, an equipment tag ID is entered (i.e.,selected from a pull-down menu or the like or is newly created), and thetechnician's name is entered (i.e., selected from a pull-down menu orthe like or is newly created).

When the install next plug icon 76 is selected, information concerningthe proposed plug is entered, i.e., plug location, plug orientation(inlet/outlet), part number/stock code, lot number, pin material, ringmaterial, plug manufacturing date, and the like may be entered. See FIG.8 . As one contemplated option, the plug may be provided with a bar codeor the like and various information may be read, automatically entered,and stored by the App by reading the barcode with the device 50. Thus, abarcode scanning icon 78 may be provided for this purpose. FIG. 9provides an example of information which might be automatically enteredinto the App for a job by scanning a barcode that may be included on alabel of box containing the plug. As an alternative, the App may be ableto automatically enter some of the information contained in FIG. 10 byentry of a lot number and subsequent automatic retrieval of informationfrom a cloud server or the like. As another alternative, some or all ofthe information may require manual entry into the App.

After the equipment (i.e., heat exchanger or pressure vessel)information and plug information is entered, an install plug or beginplug installation icon 80 may appear. Selecting this icon will lead thetechnician through the steps as outlined in FIG. 1 , the results ofwhich will be collected and stored by the App.

A user may select the reports icon 56 (see FIGS. 11 and 12 ) for aparticular job number which will provide installation details,information concerning the installed plug(s), and various installationgraphs, for instance, relating to force applied during plug installationas measured during installation. Such reports may be generated andforwarded electronically (i.e., emailed) and/or sent to a printer or thelike.

The setup icon 58 may be selected to select or modify informationrelative to existing equipment or to add information concerning newlyadded heat exchanger equipment as shown in FIGS. 13 and 14 . Searches ofequipment may be performed to view stored information concerning adesired item of equipment. The information may include, for instance,equipment tag ID, plant name, unit number, rated pressure, hydrotestpressure, and rated temperature. In addition, a user/technician may beselected to modify user information, or a new user or technician may beadded as shown in FIG. 15 . Searches by username, employee ID, or thelike may be performed. User information may include, for instance,employee ID, name, phone number, email address, and job title or thelike.

The setup icon 58 may also present the user with options to pair the Appto a separate installation tool (such as the tool shown in FIG. 2 )and/or to register the software.

The more options icon 60 may be selected by a user for the purpose ofobtaining information with respect to installation procedures, plugsizing charts, or any other information made available via the App. SeeFIG. 16 .

Example—Installation Graphs

By way of example and not by way of limitation, FIGS. 17 and 18 provideinstallation graphs having data obtained from a production test stand(FIG. 17 ) and from use of an installation tool (FIG. 18 ), such asshown in FIG. 2 , for purposes of comparison.

The graph shown in FIG. 17 provides data obtained from a production teststand in which the Y-axis relates to actual measured pulling force andthe X-axis relates to the displacement of the ring of the plug on thepin of the plug. The graph shown in FIG. 18 provides data collected froman installation tool in which the Y-axis relates to actual measuredcylinder pressure of the tool (which can be directly correlated topulling force exerted on the plug) and the X-axis relates to time.Accordingly, abnormal plug installations are able to be detected usingsuch data and the comparison thereof, even though differentcharacteristics are being measured.

While a preferred embodiment of the present invention has been describedin detail, various modifications, alterations, and changes may be madewithout departing from the spirit and scope of the present invention asdefined in the appended claims.

We claim:
 1. A device comprising at least one processor configured toverify suitability of a selected tube plug with a specificallyidentified type of heat exchanger or pressure vessel before installationof the selected tube plug, said device having at least one of an app,software, or user interface and being configured to receive or accessdata concerning the selected tube plug and received or accessed dataconcerning the specifically identified type of heat exchanger orpressure vessel and operating parameters of the specifically identifiedtype of heat exchanger or pressure vessel.
 2. The device according toclaim 1, wherein the device is an electronic device, smartphone,computer, tablet, or laptop.
 3. The device according to claim 1, whereinthe device is an installation tool configured to obtain real-timemeasurements of installation parameters.
 4. The device according toclaim 1, wherein the data concerning the selected tube plug includes atleast one of tube plug rated pressure, tube plug rated temperature, tubeplug material, and tube plug size, and wherein the data concerning thespecifically identified type of heat exchanger or pressure vessel andthe operating parameters of the specifically identified type of heatexchanger or pressure vessel include at least one of operating pressure,hydrotest pressure, operating temperature, tube material, and tube innerdiameter.
 5. The device according to claim 1, wherein the at least oneprocessor is configured to confirm tube plug installation success orfailure based on at least one real-time measurement taken duringinstallation and an analysis thereof
 6. The device according to claim 5,wherein the real-time measurement includes installation force, andwherein the analysis includes analysis of at least one of aninstallation pressure graph for chatters or for expected travel.
 7. Thedevice according to claim 1, wherein the at least one processor isconfigured to retain plug installation data and association withspecific tube location of heat exchanger or pressure vessel.
 8. Thedevice according to claim 7, wherein the device is configured toautomatically collect the tube plug installation data and to generatefeedback on the tube plug installation data.